Method and structure for joining and sealing two components

ABSTRACT

A method of joining two components of a vinyl frame provides first and second components each having an end and having surfaces defining at least one channel open at the end and extending into the associated component. A coupling structure is provided and has at least a first member and a second member and includes energy receiving structure. The first member is inserted to extend at least partially into the channel of the first component and the second member is inserted so as to extend at least partially into the channel of the second component so that the energy receiving structure is generally adjacent to certain surfaces defining the associated channel. Energy is directed to the coupling structure to cause the energy receiving structure to fuse with the certain surfaces, thereby joining the first and second components together. Improved component sealing and water pathways are also provided.

This application is a Division of U.S. application Ser. No. 10/854,188filed on Sep. 14, 2004, which is a Continuation-in-Part of U.S. patentapplication Ser. No. 10/175,021, filed on Jun. 18, 2002, which is acontinuation of U.S. patent application Ser. No. 09/679,220, filed onOct. 3, 2000, now U.S. Pat. No. 6,678,934 B1, which in turn is based onProvisional Patent Application Ser. No. 60/157,625, which was filed onOct. 4, 1999, and priority is claimed thereto.

FIELD OF THE INVENTION

This invention relates to the joining and sealing of two components and,more specifically, to the manufacture of window systems using polymerbased or metallurgy based component parts that are joined so as to havestructural integrity. In addition, this invention discloses additionalfunctionality of an internally designated or encapsulated couplingdevice to control the channeling of water while creating enhancedstructural integrity to the substrate as well as an external andinternal seal.

BACKGROUND OF THE INVENTION

A variety of methods and process for the construction of window systemassemblies have been proposed. Typically, these prior methods andprocesses require costly, complex, inconsistent, error and waste prone,susceptible to defects manufacturing steps. Generally, these priormethods and processes require a large number of pieces of equipment andskilled craftsmen. For general background, the reader is directed to thefollowing United States patent Nos., each of which is herebyincorporated by reference in its entirety for the material containedtherein: U.S. Pat. Nos. 2,037,611, 2,047,835, 2,219,594, 2,781,111,2,952,342, 3,074,772, 3,087,207, 3,287,041, 3,305,998, 3,315,431,3,327,766, 3,348,353, 3,376,670, 3,484,126, 3,802,105, 3,854,248,4,269,255, 4,327,142, 4,407,100, 4,460,737, 4,597,232, 4,941,288,5,155,956, 5,189,841, 5,491,940, 5,540,019, 5,555,684, 5,585,155,5,603,585, 5,620,648, 5,622,017, 5,799,453, 5,901,509, 6,047,514 and6,073,412. The reference to these related U.S. patent documents is notan admission of prior art, as the inventor's date of invention maypredate the date of filing and/or publication of these references.

Conventionally, in vinyl window systems, the corners of the window aredefined by cooperating miter-cut ends of two frame components that arejoined by butt-joint thermal hotplate welding. However, since the framecomponents do not have significant surface area at the abutting joint,the welded joint is not as robust. Furthermore, the conventionalhotplate welding results in undesirable divots, protrusion, score lines,etc. at the joint, and most seams need to be cleaned or scraped to bemore aesthetically pleasing. Furthermore it is most common since thisapplication includes the segregation of the components, which typicallymeans the joined or abutted components are of various profiles or linealpieces produced at alternate time frames. It is common in this processthat the two components are not siblings and due to the nature of theextrusion process these pieces create quality deficient finishes.

One of the largest drawbacks of today's hot plate welding methods, arelong cycle times for completing the complete process. The conventionalprocess consists of an alignment plate, for squaring up the ends of theextrusion that are going to be heated up. After the two adjoiningcomponents are squared up against an alignment plate, a hot plate isinserted between the two frames or sash component members and heated foran average cycle of 15 to 25 seconds. After the heating cycle iscomplete, the two ends are merged together to melt and produce a thermalweld. A cooling cycle is required before part can be removed from itstooling fixture and sent to the cleaning station. The heating cyclealone can take an average of 45 to 60 seconds for each corner. One ofthe common ways window manufactures increase throughput is by welding 4corners at once, or by stacking several frames in multiple fixtures togain efficiencies. One item that remains constant through this processis the need for a 45 to 60 second cycle per corner plus the additionalcleaning time, of which the spew or flashing can cause deflection of therequired cutter stack used in the clean up process and create either atear in the seam or dislodging of a major portion of the frame and makethe window non-usable.

Another drawback is the timeframe rendered in the production process toreveal out of square windows and/or the hardships faced by the end-usersof such finished goods when placement in the hole or setting location.Framers, contractors and homeowners face a daunting task in theinstallation process due in part to such a varying tolerance in theexternal spew of flashing left in the corner from this hotplate thermalwelding process.

Furthermore, the corners of a window should be sealed so that water canflow and exit through weep holes provided in the frame or sash. Whenthermal welding is used to join corner segments of a window the surfacearea exposed to this application is very minimal and the surface bondwhich can leave unwanted voids in the frame whereas air and waterinfiltration or leaks can occur, flash may be left behind from thethermal weld that can obstruct or block the flow of water to the weepholes.

Thus, there is a need to provide a method of joining and sealing twocomponents such as window frame components to define a robust cornerhaving smooth seams that will prevent cracking and leaking at thecorners from outside elements such as rain and condensation and thatprovides a sealed structure whereby increased surface coverage as muchas 10 times the current process occurs and specially designatedchanneling of water creates free flowing waterways to the drainage portsor weep holes.

SUMMARY OF INVENTION

An object of the invention is to fulfill the need referred to above. Inaccordance with the principles of the present invention, this objectiveis achieved by a method of joining two components, while creatinginternally and externally enhanced structural integrity to the framessystem as well increasing the seal on the internal and externalperimeter of the channeled profile, additionally providing a channel forwater to travel through the corner to provide enhanced weepingfunctionality. The method provides first and second components eachhaving an end and having surfaces defining at least one channel open atthe end and extending into the associated component. A couplingstructure is provided in a singular form or that has at least a firstmember and a second member and includes energy receiving structure. Thesingular structure is then inserted into the channel of the firstcomponent and is extending outward as so to catch or become encapsulatedinto the second member or in the case of a coupling structure thatexhibits multiplicity in origin whereas the first member is inserted toextend at least partially into the channel of the first component andthe second member is inserted so as to extend at least partially intothe channel of the second component so that the energy receivingstructure is generally adjacent to certain surfaces defining theassociated channel. Energy is directed to the coupling structure tocause the energy receiving structure to fuse with the certain surfaces,thereby joining the first and second components structurally together,while also creating a seal at the joined surfaces.

In accordance with another aspect of the invention, a method of forminga corner of a structure includes receiving material for processing, thematerial having surfaces defining at least one channel therein, cuttingthe received material to a desired length, forming at least one notch inthe material by cutting the material at certain angles, the notchdefining ends of first and second components, the first componentincluding a first portion of the at least one channel and the secondcomponent including a second portion of the at least one channel,providing a coupling structure having at least a first member and asecond member, inserting the first member to extend at least partiallyinto the first portion of the at least one channel and inserting thesecond member so as to extend at least partially into the second portionof the at least one channel, moving at least one of the first and secondcomponents so that the ends of the first and second components are ingenerally abutting relation thereby defining a corner, and directingenergy to the coupling structure to cause at least portions of thecoupling structure to fuse with at least portions of the surfacesdefining the at least one channel, thereby joining the first and secondcomponents together creating a structurally enhanced finished productand a superior sealing system.

In accordance with yet another aspect of the invention, a couplingstructure is provided that is constructed and arranged to be fused withat least one other component. The coupling structure includes a body,and energy receiving structure extending from the body. The energyreceiving structure is constructed and arranged to fuse with thecomponent when energy is directed to the energy receiving structure.

Other objects, features, functionality and characteristics of thepresent invention, as well as the methods of operation and the functionsof the related elements of the structure, the combination of parts andeconomics of manufacture will become more apparent upon consideration ofthe following detailed description and appended claims with reference tothe accompanying drawings, all of which form a part of thisspecification.

BRIEF DESCRIPTION OF DRAWINGS

In order to show the manner that the above recited and other advantagesand objects of the invention are obtained, a more particular descriptionof the preferred embodiment of this invention, which is illustrated inthe appended drawings, is described as follows.

FIG. 1 a is a window component profile, manufactured using the processof this invention.

FIG. 1 b is an alternative window component profile, manufactured usingthe process of this invention.

FIG. 2 a is a window component profile in the rotational stage of theprocess of this invention.

FIG. 2 b is an alternative window component profile in the rotationalstage of the process of this invention.

FIG. 3 a is a completed window component in the final stage ready forinstallation.

FIG. 3 b is an alternative completed window component in the final stageready for installation.

FIG. 4 is a process flow diagram of the preferred method of thisinvention.

FIG. 5 is a detailed flow chart of the present, typically although notnecessarily automated, process of this invention.

FIG. 6 is a perspective view of a coupling structure provided inaccordance with the principles of the invention.

FIG. 7 is a perspective view of the coupling and sealing structure ofFIG. 6 shown in position to be placed into a notch defined between twocomponents of a window.

FIG. 8 is a perspective view of the coupling and sealing structure ofFIG. 6 shown in inserted into the notch between the components of FIG.7.

FIG. 9 is a perspective view of coupling structure of FIG. 6 shown witha breakable portion thereof in a separated condition defining first andsecond portions of the coupling structure with a portion being disposedin channels of an associated component.

FIG. 10 is a perspective view of the first and second portions of thecoupling structure FIG. 9.

FIG. 11 is perspective view of the second component of FIG. 9 shownbeing moved about a hinge connection.

FIG. 12 shows a perspective view of the coupling and sealing structurein position when the first and second components are in the positionsshown in FIG. 11.

FIG. 13 is a perspective of first and second components and coupling andsealing structure therein, defining a corner of a window.

FIG. 14 shows a perspective view of the coupling structure in a lockingposition when the first and second components are in the positions shownin FIG. 12.

FIG. 15 is an exploded assembly view of coupling structures of a secondembodiment of the invention.

FIG. 16 is a perspective view of another embodiment of the couplingstructure of the invention for use as a corner of a nail fin.

FIG. 17 is a perspective view of a window corner having a nail fin.

The reader should understand that the drawings depict only a presentpreferred and best mode embodiment of this invention, and are not to beconsidered as limiting in scope.

Reference will now be made in detail to the present preferred embodimentof the invention, examples of which are illustrated in the accompanyingdrawings.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EXEMPLARY EMBODIMENTS

FIG. 1 a shows a window component profile, manufactured using theprocess of this invention. This preferred embodiment of the windowcomponent has three generally elongate sections 101 a, 101 b, 101 c andtwo half sections 102 a, 102 b, each connected 113 a, 113 b, 113 c, 113d to an adjacent section. In alternative embodiments, when it is desiredto have windows with non-rectangular shapes, the number of sections canbe increased or reduced. For example, a triangular shaped window mayhave only two long sections and two half sections. In another example,an octagonal shaped window may have seven long sections and two halfsections. The connections 113 a, 113 b, 113 c, 113 d are flexiblepermitting a bend at the connection 113 a, 113 b, and 113 c, 113 d. Thepreferred elongate sections 101 a, 101 b, 101 c and half sections 102 a,102 b are preferably made of a composite material, molded, cut, milled,routed or otherwise shaped in to the desired generally decorative shape.While the sections 101 a, 101 b, 101 c are shown, in this embodiment, asbeing of generally the same length, in alternative embodiments, thesections 101 a, 101 b, 101 c may have different lengths as appropriateto the desired window shape. Each section 101 a, 101 b, 101 c isprovided with two diagonal cut sloped portions (respectively 105, 106;107, 108; and 109, 110). These diagonal cut sloped portions 105, 106,107, 108, 109, 110 are shown having an angle of 45 degrees, however, inalternative embodiments this angle may be either increased or decreasedas necessary in order to facilitate the joining of two adjacent diagonalsloped portions, to thereby produce a window component having thedesired shape. The ends 103 and 112 are, in this embodiment, atapproximately 90 degrees from the base 100 of the window portions,thereby facilitating the joining of the ends 103, 112, as shown in FIG.3 a.

FIG. 1 b shows an alternative window component profile, manufacturedusing the process of this invention. This second preferred embodiment ofthe window component has four generally elongate sections 114 a, 114 b,114 c, 114 d each connected 116 a, 116 b, 116 c to an adjacent section.In alternative embodiments, when it is desired to have windows withnon-rectangular shapes, the number of sections can be increased orreduced. For example, a triangular shaped window may have only threelong sections. In another example, an octagonal shaped window may haveeight long sections. The connections 116 a, 116 b, 116 c are flexiblepermitting a bend at the connection 116 a, 116 b, 116 c. The preferredelongate sections 114 a, 114 b, 114 c, 114 d are preferably made of amaterial, molded, cut, milled, routed or otherwise shaped in to thedesired generally decorative shape. While the sections 114 a, 114 b, 114c, 114 d are shown, in this embodiment, as being of generally the samelength, in alternative embodiments the sections 114 a, 114 b, 114 c, 114d may have different lengths, as appropriate for the desired windowshape. Each section 114 a, 114 b, 114 c, 114 d is provided with twodiagonal cut sloped portions (respectively 115 a, 115 b; 115 c, 115 d;115 e, 115 f; 115 g, 115 h). These diagonal cut sloped portions 115 a,115 b, 115 c, 115 d, 115 e, 115 f, 115 g, 115 h are shown having anangle of 45 degrees, however, in alternative embodiments this angle maybe either increased or decreased as necessary in order to facilitate thejoining of two adjacent diagonal sloped portions, to thereby produce awindow component having the desired shape. The joining of the ends 117,118 are as shown in FIG. 3 b to form the complete window component.

FIG. 2 a shows a window component profile in the rotational stage of theprocess of this invention. This view shows the window component of FIG.1 a, with the diagonal sloped portions 106, 107 and 108, 109 broughtinto contact and joined to form corners 201, 202 and thereby the bottom205 of the window component.

FIG. 2 b shows an alternative window component profile in the rotationalstage of the process of this invention. This view shows the windowcomponent of FIG. 1 b, with the diagonal sloped portions 115 b, 115 cand 115 d, 115 e brought into contact and joined to form corners 203,204 and thereby the bottom 206 of the window component.

FIG. 3 a shows a completed window component in the final stage ready forinstallation of the window component of FIG. 1 a. Ends 103 and 112 areconnected forming a joint 301 at the top 309 of the window component.Diagonal sloped portions 104, 105 and 110, 111 are brought into contactand joined to form corners 302 and 303 and to define an interior 307suitable for holding and retaining glass or other similar transparent orsemi-transparent material. The joints 301, 311, 312, 313, 314 aretypically and preferably made using Sonic applications or energydirected techniques as described below, although alternatives such asadhesive, bolts, screws, pins, clips and the like can be substitutedwithout departing from the concept of this invention.

FIG. 3 b shows a completed window component in the final stage ready forinstallation of the window component of FIG. 1 b. Ends 117 and 118 areconnected forming a joint 315 of the diagonal sloped portions 115 a, 115h, thereby forming a corner 304. Diagonal sloped portions 115 f, 115 gare brought into contact and joined to form corner 305 and to define aninterior 308 suitable for holding and retaining insulating glass orother similar transparent or semi-transparent material. The joints 315,316, 317, 318 are typically and preferably made using Sonic applicationsor energy directed techniques as described below, although alternativessuch as adhesive, bolts, screws, pins, clips and the like can besubstituted without departing from the concept of this invention.

FIG. 4 shows a process flow diagram of a method of this invention.Initially, the material is fed 400 into the assembly process. Next, thematerial is straight cut 401 preferably by a saw or mill machine. Thecut material is set 402 for Lifter or Balance Holding punch, preferablyon a drill or router machine. The material is then punched 403 for thelifter clip, also preferably on a drill or router machine. Weep punching404 is next performed on the material, again typically using a punch,drill or router machine. These punching steps are used to provideventilation and drainage points in the window component. Miscellaneousprocessing 405 is performed to remove loose material and/or rough edges.A first three-way cut, or notch, 405 is made, to produce diagonalportions, preferably using a cutter, grinder, or corner set. A secondthree-way cut 406 is made, to produce additional diagonal portions, alsopreferably using a cutter, grinder or corner set. A second weep punch408 is made to further provide additional drainage and ventilation,preferably using a drill or router machine. In step 409, a polymercompound is applied to the joint regions thereby providing durable,flexible corners. Identification markings are applied 410 to permitcontrol and tracking of window components. The assembly or windowcomponent is rotated with the corner and/or end portions joined togetherusing adhesive, screws, bolts, clips, pins or the like forming thecomplete window component ready for the insertion of the transparentmedium and for installation in the building structure.

FIG. 5 shows a detailed flow chart of the present, typically althoughnot necessarily automated, process of this invention. This presentembodiment of the invention may employ automation techniques andtechnology to improve the quality and consistency of the manufacturingprocess while simultaneously reducing labor and material costs. Althoughthe steps of the process shown in this FIG. 5 accommodate automationtechnology, the reader should understand that in alternative envisionedembodiments, the steps can be performed in a manual fashion. Dataprofiles are received 501 by a control processor. A typical controlprocessor is a programmable computer, although alternative processors,such as single purpose electronic devices could be substituted withoutdeparting from the concept of this invention. The data profiles includeinformation related to the desired window shape, size, texture, color,frame material (also referred to herein as construction material), glassor other medium type and/or other features typically specified in theconstruction of window frames. Frame window materials are typicallyselected from but are not necessarily limited to composites, plastic,metal, and wood reinforced with a foldable back portion. Texturesinclude patterns, roughness and the like in the surface of theconstruction material. Window shapes supported by this invention includesquare, rectangular, triangular, octagonal, and other polygonal shapes,circular, oval and other curved shapes. Moreover, the window shapes maybe either an irregular or normal polygon, and includes trapeziums, halfrounds, and ellipses. The data profile also typically includesdimensional information, such as height, width and thickness of desiredframe(s). This dimensional information may be input, or received by theprocessor in various units, including either English units (inches,feet, yards) and/or metric units (centimeters, meters). The data profilealso includes information concerning the type and size of desiredtransparent, or semi-transparent, material. Typically, this material isglass, although plastic, acrylic, composite or other generallytransparent, window compatible material can be substituted withoutdeparting from the concept of this invention. Also, typically describedin the data profile is the frame material, color and texture used anddesired, as well as such other window-type features, such as single panewindows, double pane windows, horizontal sliders, single or double hungsliders, patio doors, shaped windows, picture windows, and other typesof windows known in the art.

The control processor, which may be a distributed processor incommunication with a processor receiving the data, a separate processorcomputing, and a still other processor controlling the manufacturingequipment and perhaps a further processor tracking the process of thewindow components through the process of this invention, computes 502the cutting and notching of the received material. This computation step502 preferably includes calculating the length of window framecomponents (which will be produced from the received material)calculates and/or selects the positioning of the notches within eachwindow frame component, as well as the angle of the sloped or “notch”portion as well as the distance between notches. In general, for aregularly shaped square or rectangular window, the notch angles would be45 degrees and the number of elongated sections would be four, while foran octagon the notch angles would be 22.5 degrees and the number ofelongated sections would be eight. In order to provide certain curvedwindow shapes the notch angles may also be non-linear. The notch anglesare selectable generally from 0 degrees to 180 degrees to provide for aselection of a generally continuous set of window shapes. The number ofnotch angles is also selectable, with four angles in each notch beingtypical. The data treatment calculation may include tolerance rangesfrom 0.000 inches to 0.500 inches to account for potential stretching ofvarious construction materials. Construction materials are received 503.Typically, these construction materials are received in a single pieceform and often have a nail fin provided on the outer surface area. Acutter is provided to perform the cutting operation for cutting thereceived construction materials to the required length of the windowframe component and to create the notches defining the sections (alsoreferred to as elongated sections) of the window component. Typically,this cutter is a mill, router, saw, compression metal cutter,high-pressure water jet cutter, heat or torch cutter, and the like. Awide variety of construction materials may be used with this invention,including, but not necessarily limited to vinyl, plastic, polymers,wood, metal, fiberglass and/or other composite materials.

Once the construction materials are received 503, the processoractivates 504 the cutter using the notching sequences previouslycalculated to perform the cutting and notching sequences on theconstruction material to produce a linear physical profile. In thepresent embodiment this activation 504 is a batch computation process.In the present embodiment, a mill cuts 505 the construction material tolength and cuts the angled notches in the construction material todefine the sections. In one present embodiment the angled notches aremade sequentially, in other embodiments multiple angled notches are madesimultaneously or at least with several cutters operating independentfrom each other. In one embodiment of the process movement of theconstruction material is done automatically, while in other embodiments,a person may be required or prompted to move the material as required toposition for angled notching. In some embodiments, the angled notchesdefine sections of equal length, in other embodiments; the anglednotches define sections of unequal length. Typically, a three-way notchor cut is provided to produce the diagonal partial cut-through notchesof the present embodiment. Drilling or punching 506 operations may thenbe performed to introduce openings in the construction material fordrainage, air filtration, placement of hardware, routing of conduitand/or dimpling. A composite material may then be applied 507 to thesurface of the construction material to improve flexibility, durabilityand weather proofing of the resulting frame. The selected compositematerial applied is selected to be appropriate to the constructionmaterial, and is typically a polymer compound with high temperaturetolerance and moisture resistance. An adhesive material, typically achemical or polymer adhesive, could be applied 508 to the angled notchportions to assist in the adhesion of the after folded corners or thepreferable method would be Sonics or energy directed applications.

After the typically batch system has completed cutting operations 505,the construction material is folded 509 to form one or more corners fromthe ends of the individual sections. During and/or after the foldingstep 509 additional adhesive may be injected to provide a seal in thefolded corners. After folding 509, the construction material takes onthe shape of the desired window shape, such as a square, rectangle orother selected shape identified in the received 501 data, and aninterior adapted to hold in place the selected transparent medium. Theselected transparent medium is typically glass, although alternativesincluding plastic, acrylic and other similar transparent orsemi-transparent materials can be substituted without departing from theconcept of this invention. In an alternative embodiment, theconstruction material is folded 509 after each angled notch cuttingoperation 505, so that with each fold, the appearance of the materialincreasingly resembles the desired shape and selected data profile. Asecond typically polymer composite, adhesive, material could be injected510 in each corner thereby affixing the construction material in thedesired shape or the more preferable the use of Sonic or energy directedapplications would take place. This second polymer composite alsoenhances the seal in the corners and may be used to retain thetransparent medium in place in the interior of the frame component.After folding the section ends, including the ends (see 103 and 112 ofFIG. 1 a) of the component and the angled notches (cumulatively nowcorners) are fixed 511 in place, typically through the injection of thesecond polymer, through the use of the adhesive of step 508 oralternatively by the use of metal joining or metallurgical process (suchas welding and the like) or mechanical fastener devices (such as screws,brackets, bolts and the like). Composite material is typically applied512 to the exterior portions of the construction material to provide adesired finish to the frame component. Throughout the process of thisinvention, the components are presently tracked 513 for inventory andquality control purposes. In some embodiments, the tracking 513 may befacilitated by identification marking of the window components,construction materials and/or sections for automatic or manualdetection.

In order to make the corners of the window system even more robust, inaccordance with another aspect of the invention, a coupling structure,generally indicated at 620 in FIG. 6, is to be secured in each corner ofa frame. FIG. 7 shows two sections or components 101 a, 101 b of a framejoined by a flexible hinge connection 113. The respective ends 600 a,600 b of the components 101 a, 101 b include the above-mentioneddiagonal cuts (forming a notch 611) so that when joined, cooperate todefine a corner of the frame, as will be explained more fully below. Itcan be appreciated that the two components can be separated, (e.g., nothaving the hinge connection 113). As shown in FIG. 7 each component 101a, 101 b has surfaces defining at least one respective channel 610 a,610 b open at the end or notch 611 and extending into the associatedcomponent. In the illustrated embodiment, each component 101 a, 101 bincludes a central channel 610 a, 610 b, side channels 612 a, 612 b, and614 a, 614 b, and a bottom channel 616 a, 616 b, respectively. Due tothe notch 611, each channel in component 101 a appears to be separatefrom each channel in components 101 b. However, the channels 610 a and610 b can be considered to be portions of the same channel. This appliesto channels 612, 614 and 616 as well.

In the embodiment of FIG. 6 the coupling structure 620 has at least afirst member 622 and a second member 624 operatively associated with thefirst member 622. Members 622 and 624 can be separate members orintegral members. As shown, the coupling structure also includesco-operating members 626 and 628 at one end thereof, and co-operatingmembers 630 and 632 at the other end thereof. Cooperating first bridgingmembers 623, 625 extend between members 622, 624 and the members 626,628, and cooperating second bridging members 627, 629 extend between themembers 622, 624 and the members 630, 632. Each bridging member 623,625, 627 and 629 includes elongated channels 631 there-through definingpathways to permit water and air to pass when disposed in the bottomchannel 616 as will become apparent below. Bridging members 623 and 627can be considered to be a single structure and bridging members 625 and629 can also be considered to be a single structure.

The coupling structure 620 include energy receiving structure 634 on atleast a portion of the periphery thereof so as to be disposed generallyadjacent to certain surfaces defining the associated channel 610 a, 610b, 612 a, 612 b, 614 a, 614 b, 616 a, 616 b, when the members 622, 624,626, 628, 630, 632, 623, 625, 627 and 629 are disposed in a respectivechannel. In the illustrated embodiment, the energy receiving structure634 is in the form of spaced ribs that extend from the couplingstructure, but are not limited to this configuration. The energyreceiving structure 634 can be of any configuration that can be causedto be fused to other surfaces, as will be explained below.

In the illustrated embodiment and best shown in FIG. 10, members 624,623, 626 627 and 630 are integral and form a first portion 635 of thecoupling structure 620 associated with component 101 a. Members 622,625, 628, 629 and 632 are integral and define a second portion 637 ofthe coupling structure 629 that is associated with component 101 b.Preferably, the first and second portions 635, 637 of the couplingstructure 620 are joined (FIG. 6) by a breakable portion or seam 636 sothat the coupling structure 620 can be placed with respect to components101 a, 101 b in one movement. Thereafter, the breakable portion can bebroken to separate the two portions of the coupling structure 620 (FIG.10).

A method of joining the coupling structure 620 to the components 101 a,101 b, will be described with regard to the first and second members622, 624, and the channels 610 a, 610 b, respectively, for ease ofexplanation. With reference to FIG. 7, the first and second components101 a, 101 b, are oriented to be disposed more than 90 degrees apart(e.g. 180 degrees as shown) with respect to the hinge connection 113.The coupling structure 620 is positioned with respect to the first andsecond components 101 a, 101 b. Next, as shown in FIG. 8, the couplingstructure is further assembled with the first and second components 101a, 101 b and the breakable portion 636 is broken so that the first andsecond portions 635, 637 of the coupling structure 620 and thus, members622, 624 are separated from each other in an associated channel. As thisstage, coupling structure 620 is as shown in FIG. 10. As shown in FIG.9, the first member 622 is extended at least partially into the channel610 a of the first component 101 a and the second member 624 is extendedat least partially into the channel 610 b of the second component 101 bso that the energy receiving structure 634 is generally adjacent tocertain surfaces defining the associated channel.

Next, with reference to FIG. 11 the first component 101 a is moved abouthinge connection 113. At this stage, the position of the couplingstructure 620 is shown in FIG. 12. The first and second components 101a, 101 b are oriented so as to be generally 90 degrees apart so that theends 600 a, 600 b are in generally abutting relation (FIG. 13).

As best shown in FIG. 12, the first and second members 622, 624 of thecoupling structure have co-operating locking structure. Member 622 has aprotruding key that is received in keyway 639 of the member 624. Ofcourse, the mating parts can be reversed. The locking structure can takeany form that permits the members 622 and 624 to interlock. Thus, whenfirst and second components 101 a, 101 b are oriented to be generally 90degrees apart (FIG. 13), the first and second members interlock via thelocking structure as shown in FIG. 14).

In this closed, interlocked condition, energy is directed to thecoupling structure 620 to cause the energy receiving structure 634 tofuse (e.g., be integrally joined) with the certain surfaces of thechannels, thereby ensuring that the coupling structure 620 is integrallyjoined with the each of the first and second components 101 a, 101 b,respectively, so as to join the first and second components together.

In the illustrated embodiment, vibrational energy is used to causevibration of each member 622, 624 with respect to the surfaces of theassociated channel. When this occurs, the energy receiving structure 634melt (fuse) to create an integral joint between the coupling structureand the surfaces defining the channels 610 a, 610 b. The vibrationalenergy can be delivered via a conventional ultrasonic sonic assemblyhaving, for example, a generator that changes electrical power intoelectrical energy at a frequency such as 20 to 40 kilohertz, atransducer that converts the electrical energy of the generator into lowamplitude mechanical motion or vibrations, a booster that increases ordecreases the amplitude of the vibrations, and a horn of the proper sizeand shape to deliver the vibrational energy to the members 622, 624.Thus, vibration external to the components 101 a, 101 b causes fusing ofthe internally located coupling structure 620 to the components 101 a,101 b. In the embodiment, parameters used in the fusing process were: 20MHz power, 40 psi pressure and 0.750 second fusion time, with a 1.5booster and an aluminum substrate with a chrome plated horn.

Since the first and second members 622, 624 of the coupling structure620 extend within the channels 610 a, 610 b, the surface area of theconnection between the coupling structure 620 and the first and secondcomponents 101 a, 101 b is substantially increased as compared to theconventional butt-welded joint.

It can be appreciated that when the first and second members 622 and 624are joined with the associated component 101 a, 101 b, the members 626,628, and members 623, 625 and members 627, 629 and members 630, 632 arealso fused with the associated component 101 a, 101 b. With reference toFIG. 14, it can be appreciated that the bridging members 623 and 625 andbridging members 627 and 629 strengthen the corner and cooperate todefine air and water pathways for enhancing weepage in the windowsystem, as will be explained more fully below. Also, members 630 and 632cooperate to strengthen one outer corner portion of the overall cornerand members 626 and 628 cooperate to strengthen the other outer cornerportion of overall corner. In that regard, and as shown in FIGS. 11 and12, member 626 has a portion including surface 652 that extends intochannel 614 b to mate or be abutting with surface 650 of member 628 whenassembled. These surfaces 650, 652 mate beyond the seam line 654 (FIG.13) and ensure a smooth, clean outer seam line. In addition, whenjoined, members 626 and 628, members 630 and 632 and members 622 and 624cooperate to define plugs to seal air and water, so that air and watermay flow unobstructed and without leakage through the air and waterpathways and thus to weep holes (not shown). Thus, no water can leakpast the joint.

Thus, the integrity of the structure of the joint and the sealingproperties of the embodiment is increased substantially. The couplingstructure 620 distributes the pressure off of the corner seam-line andmoves it to a number of places throughout the corner. In addition, thefusion of the coupling structure 620 with the components defines agenerally smooth seam at the corner, thus, no divots, protrusions etc.that result from the conventional butt-welded corner occur.

Although fusing by employing vibrational energy is disclosed, it can beappreciated that other types of energy may be used such as heat energy,a chemical reaction (catalyst application), compression, or any otherenergy that is capable of joining components. Furthermore, in additionto, or in lieu of, fusing, adhesives and injection molding can be usedto secure the coupling structure 620 with the first and secondcomponents 101 a, 101 b, respectively.

In the embodiment the first and second components 101 a, 101 b arepreferably composed of vinyl material and the coupling structure iscomposed of plastic, preferably Acrylonitrile Butadiene Styrene (ABS).Materials of amorphous or semi-crystalline nature are within thecontemplation of the invention. Since the coupling structure 620 isinternal of the components 101 a, 101 b when finally assembled, thematerial thereof needs not meet weatherability and UV stabilizationrequirements.

Another embodiment of the coupling structure 620′ is shown FIG. 15. Thecoupling structure 620′ is a single component preferably having a firstmember 622′ and an integral second member 624′. Each member has energyreceiving structure 634′ on at least a portion thereof to be fused tosurfaces defining an associated channel 700 of a component 710, in themanner discussed above to join the two components 710. The couplingstructure 620′ also includes a pathway 631′ for water and air flow.Thus, the joint formed by the coupling structure 620′ is sealed by thecoupling structure and water passes only through the pathway 631′.Hence, the invention is thus applicable to any structure having achannel therein.

With reference to FIGS. 16 and 17, the invention is also applicable toimproving the nail fin 720 of a window. Conventionally, there is nocorner defined on a nail fin of a window corner and the nail fin canbecome damaged in assembly or transport. With reference to FIG. 16, tostrengthen the nail fin, a coupling structure 620″ is located withrespect to adjacent nail fins 720 by clips, snap-fit arrangement 730,etc. The coupling structure 620″ includes energy receiving structure634″ that is fused with a portion of each nail fin 720. The couplingstructure 620″ preferably has a rounded portion to define a roundedcorner so as to be resilient to bumps and drops that commonly occur inthe installation process. Thus, a robust corner is provided on the nailfin.

Although the invention has been described with regard to window systemsand in particular 90 degree corners thereof, it can be appreciated thatthe invention is applicable to doors, gates, or any structure that hascomponents that are required to be joined at angles from about 20 to 180degrees to form corners or other joints. The locking structure of thecoupling structure can be constructed and arranged to lock at a varietyof selected angles to accommodate joints of different angles.Furthermore, the invention is applicable to forming joints in structureshaving shapes other than square or rectangular. For example, polygonalstructures, and/or structures having curved portions are within thecontemplation of the invention.

The described embodiments of this invention are to be considered in allrespects only as illustrative and not as restrictive. Although specificsteps and window system components are illustrated and described, theinvention is not to be limited thereto. The scope of this invention is,therefore, indicated by the claims. All changes, which come within themeaning and range of equivalency of, the claims, are to be embraced asbeing within their scope.

1-20. (canceled)
 21. A coupling structure constructed and arranged to befused with at least one other component, the coupling structurecomprising: a body, and energy receiving structure extending from thebody, the energy receiving structure being constructed and arranged tofuse with said one component when energy is directed to the energyreceiving structure.
 22. The coupling structure of claim 21, wherein thebody includes at least a first and a second member, the first and secondmembers having cooperating locking structure so as to be capable ofbeing interlocked.
 23. The coupling structure of claim 21, wherein theenergy receiving structure includes a plurality of ribs disposed inspaced relation on at least a portion of the body.
 24. The couplingstructure of claim 21, wherein the first and second members are joinedvia a breakable portion, the breakable portion being constructed andarranged to broken to separate the first and second members.
 25. Thecoupling structure of claim 21, in combination with two components, eachcomponent having an end and having surfaces defining at least onechannel extending from the end into the associated component, the bodyincluding at least a first member and a second member, each memberextending at least partially into an associated channel and each memberincluding said energy receiving structure, wherein the energy receivingstructure is joined with surfaces defining the associated channel. 26.The coupling structure of claim 21, in combination with two componentsarranged to define a corner of a structure, each component having acentral channel, a first side channel, a second side channel, and bottomchannel, wherein respective channels of one component communicate withassociated channels of the other component, the body including: a firstmember and a second member, each extending at least partially into anassociated central channel, a third member and a fourth member, eachextending at least partially into an associated first side channel, afifth member and a sixth member, each extending at least partially intoan associated second side channel, and a seventh member and eighthmember, each extending at least partially into an associated bottomchannel, wherein each member includes said energy receiving structurefused with certain surfaces defining an associated channel.
 27. Thecombination of claim 26, wherein the seventh and eighth members areconstructed and arranged to define a passage in the bottom channel topermit water to pass, with the first and second members, the third andfourth members, and the fifth and sixth members defining seal structureso as to prevent leakage of water from the passage.
 28. The combinationof claim 25, wherein the first and second members have cooperatinglocking structure so as to be interlocked.
 29. The combination of claim24, wherein the third member has a portion that extends into the channelcontaining the fourth member and abuts a portion of the fourth member.30-39. (canceled)